Pouch Filler Granulation With Binder Separation for Uniform Particle Size
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Solution Overview
Problem
Existing methods for preparing pouch fillers face issues with increased viscosity due to high binder content, leading to lumping and reduced manufacturing workability, and difficulty in achieving uniform particle sizes.
Innovation Solution
A method involving the preparation of a particle size control solution with a processing aid, spraying it onto a solid-phase filling material containing a binder, followed by granulation and low-temperature drying, with specific binder and processing aid ratios to maintain low viscosity and prevent lumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the content of binder in the granulizing solution is increased to adjust particle size characteristics, then the particle size distribution is improved, but the viscosity of the granulizing solution increases reducing manufacturing workability
Solution Approach 1:
The invention extracts the binder from the granulizing solution and places it only in the solid-phase filling material. This separation allows the granulizing solution to maintain low viscosity (good workability) while the binder in the solid material provides the necessary particle size control during granulation, resolving the contradiction between particle size precision and manufacturing workability.
Solution Approach 2:
The invention changes the parameter of binder location from 'dissolved in solution' to 'embedded in solid material'. This parameter change allows the system to achieve particle size control through the solid-phase binder release during granulation, while the liquid phase remains viscosity-free for easy processing.
2Ease of manufacture
If the content of processing aid in the granulizing solution is increased to lower viscosity, then manufacturing workability is improved, but lumping occurs during filler preparation degrading workability
Solution Approach 1:
The invention removes the processing aid from the granulizing solution entirely, replacing it with water or alcohol. The binder function is transferred to the solid-phase material, eliminating the need for processing aids that cause lumping when overused, thus maintaining both workability and process stability.
Solution Approach 2:
The invention introduces water or alcohol as an intermediary substance to replace the problematic processing aid. These intermediaries provide the necessary liquid phase for granulation without causing the lumping effect, maintaining process stability while preserving manufacturing workability.
3Manufacturing precision
If binder content is adjusted to control particle size, then particle size characteristics are improved, but viscosity increases reducing ease of operation
Solution Approach 1:
The invention extracts the binder from the liquid phase and places it in the solid phase. This allows particle size control to be achieved through the solid-phase binder during granulation, while the liquid phase remains free of viscosity issues, simultaneously improving particle size characteristics and ease of operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves excellent manufacturing workability and uniform particle sizes, ensuring a uniform particle size distribution without lumping, enhancing the quality of the pouch filling material.
Implementation Method 1
step S3 of spraying the particle size control solution onto the solid-phase filling material while stirring the solid-phase filling material
Implementation Method 2
step S5 of performing drying at a temperature of room temperature to 80°C for 2 to 5 hours after step S4
Data Source
Figure 1
AI summary
The present invention provides a method for preparing a pouch filler material, comprising the steps of: (S1) preparing a solid filler material including a binder; (S2) preparing a particle size control solution including a processing aid; and (S3) spraying the particle size control solution onto the solid filler material while stirring the solid filler material.